Mold apparatus for casting molten metal

ABSTRACT

A series of molds, each having a casting cavity defined by a plurality of movable mold blocks, are positionable to be successively filled with molten metal from a movable ladle. After the metal in each mold solidifies, the mold blocks are moved and the enclosed casting is transported to another location for processing. Cleaning and coating apparatuses are provided to recondition the mold blocks after each pour. The reconditioned blocks are then repositioned to define a casting cavity and moved into a pouring location to be again filled with molten metal.

United States Patent [72] Inventor Edmund Q. Sylvester c/o Sylvester Enterprises, Inc. 850 Hanna Bldg., Cleveland, Ohio 441 15 [21] Appl. No. 527,699 [22] Filed Feb. 16, 1966 {45] Patented Sept. 14, 1971 [54] MOLD APPARATUS FOR CASTING MOLTEN METAL 25 Claims, 14 Drawing Figs. [52] 11.8. CI 164/269, 164/137, 164/158, 164/270, 164/323, 164/342, 249/158, 249/162 [51] Int. Cl ..,.B22d 47/00, B22d 33/04 [50] Field of Search 164/323, 270, 267, 269,158,137, 72, 341, 339, 405, 342, 343;249/158,161,162

[56] References Cited UNITED STATES PATENTS 868,730 10/1907 Tubesing 25/D1G. 17 1,495,728 5/1924 Dostal H 164/158 X 12/1934 RUSSellelal 164/72 2,864,141 12/1958 Vallak 249/162 3,060531 10 1962 Maring... 164/405 3,189,960 6/1965 Bright..... 164/323x 3,262,164 7/1966 Meves.... 164/341 3,340,926 9/1967 Sylvester 249/15sx FOREIGN PATENTS 62,707 3/1891 Germany 164/323 Primary Examiner-J. Spencer Overholser Assistant ExaminerJohn E. Roethel At1omeys-Walter L. Schlegel, Jr. and Ralph M. Faust PATENTEI] SEP 1 4mm 3,604,497

sum 5 0F 6 MOLD APPARATUS FOR CASTING MOLTEN METAL The present invention relates to mold apparatus and method of casting.

A principal object of the invention is to provide mold apparatus and a method of casting whereby to provide steel articles such as slabs and billets in a mold that can be worked immediately from the mold into final commercial items without the necessity for treating them in intermediate processes.

A principal advantage of the invention resides in the fact that the product resulting from the use of the method and apparatus of the invention, in the form of a slab or billet, is in such near-perfect condition that it can be immediately rolled into a final commercial item substantially without defects. Heretofore final castings have been fraught with so many blemishes and deformations and other defects that it was necessary to treat the casting by operations that were extremely expensive and added objectionably to the final product cost. In the present case the mold apparatus of the invention is so constructed that it is capable of producing a regular and uniform surface item, such as a slab or billet, of such nearly perfect proportions and dimensions that it is possible to further treat the item, as by rolling, so that the final product is substantially free of defects.

An object of the invention is to provide mold apparatus of such novel construction as to be capable of producing castings of the type referred to above having near-perfect dimensions and without defects, to a degree difficult of attainment heretofore.

Another object is to provide mold apparatus of the character referred to above in which the mold is made up of a plurality of blocks individually mounted and movable into and out of casting position in which they define a cavity in which a slab or billet is cast and which can be individually removed from such a position to expose the resulting casting which can then be immediately subjected to further treatment such as rolling for converting it into commercial items and shapes, such as rods, structural shapes, etc.

A further object of the invention is to provide molding apparatus of the foregoing general character in which the mold apparatus includes a pair of side blocks and a plurality of inner blocks associated therewith and which with the side blocks form a casting cavity, in which the side blocks can be separated for exposing the resulting casting, and other ones of the blocks of the mold are moved out of the casting position, whereby the casting can easily be removed from its casting position and put into a position for further treatment, e.g., conveying it to another area, or presenting it to other apparatus for further treatment.

A still further object is to provide apparatus of the foregoing general nature in which the mold apparatus is of such character that a plurality of molds can be provided in side by side relation, and the inner blocks which are moved out of the main mold structure for exposing the casting, can be so moved alternately in opposite directions, whereby in a single mold a pair of sets of inner blocks can be provided for alternately moving them out opposite ends of the mold with the result that while one set is removed from the mold for presenting the casting thereon for further treatment, the other set is ready, after previous treatment, for moving it into casting position, and thereby increasing the capacity of a single mold apparatus.

A further object is to provide mold apparatus of the foregoing general character which includes a novel arrangement involving hanging certain of the parts of the mold which increases the efficiency of the operation of the mold.

A still further object of the invention is to provide an arrangement of molds of the character just referred to which includes hanging certain parts of the molds whereby to increase the efficiency in assembling the molds for the casting operation and disassembling them for removing the resulting castings.

Still another object is to" provide mold appara'tusof the foregoing general character made upof-a'pluralit'y of parts'or blocks which are mounted in a novel manner for facilitating quickly placing them in an assembledposi tion for a casting operation, and removingthem from that position for facilitating and expediting the removal of the resulting casing from the V mold.

A still further object of the invention is to provide-apparatus of the foregoing general character including side blocks which constitute the principal or largest portion of the mold apparatus and which are disposed generally in a single location, and including an arrangement whereby upon the completion of a casting operation, the side blocks can be'separated from each other for exposing the casting, while remaining in the same general location, for enabling removal of the casting from that location to another location for further treatment thereof.

Another object of the invention is to provide apparatus for casting and treating steel whereby steel can be cast in such forms as slabs and immediately worked into shapes such as plate or strip suitable for fabrication, to the exclusion of other formation steps.

Other objects and advantages of the invention will appear from the following detail description taken in conjunction with the accompanying drawings wherein FIG. 1 is a small scale perspective view, semidiagrammatic in nature, showing the principal parts of a mold embodyingthe present invention;

FIG. 2 is a side view of an assembled mold made up of the parts of FIG. 1 assembled into position;

FIG. 3 is a top view of the mold in assembled condition;

FIG. 4 is a perspective view of a casting made in the mold;

FIG. 5 is a plan view of a plant layout utilizing molds made according to the present invention;

FIG. 6 is a large scale sectional view taken at line 6--6of FIG. 5;

FIG. 7 is a large scale taken at line 7-7 of FIG. 5, and showing the different molds in difierent positions;

FIG. 8 is a small scale perspective view of a car having racks thereon for receiving cast slabs;

FIG. 9 is a transverse vertical sectional view of an arrange ment similar to FIG. 6 but showing a slightly modified arrangement;

FlG. 10 is an end view of a mold showing one kind of apparatus for washing the mold;

FIG. 11 is a transverse vertical sectional view showing a mold made according to the present invention together with apparatus for receiving the slab cast in the mold and positioning it for further treatment;

FIG. 12 is a semidiagrammatic view, on a small scale and oriented according to a view from the left of FIG. 11, but indicating additional components;

FIG. 13 is a plan view taken at line l3-I3 of FIG. 12; and

FIG. 14 is a perspective view of one of the components represented in FIG. 12.

Referring now in detail to the drawing, attention is directed first to FIGS. 1, 2, and 3. In these figures the mold, indicated in its entirety at 20; includes a number of blocks that are completely separable from one another, enabling adjustment of the mold for forming cavities of selectively different sizes, and production of castings of even and regular outline, the blocks of the mold each having, for the most part, a plane surface for that purpose. The block include a pair of side blocks 22 and 24, a bottom block 26, a top block 28,a rear end block 30 and a front end block 32, all preferably of graphite. These blocks are mounted for moving them into and out of position by power means as will be explained in detail hereinbelow. Briefly, the two side blocks 22 and 24 are movable toward and from each other, and the other blocks 26, 28, 30 and 32 together constitute a group of inner blocks that are gripped between the main'side blocks for forming a cavity 34 in which the casting is formed. The rearend block 30 is adjustable longitudinally in the assembly'for determining the length of the cavity 34 and hence the length of the casting. Also the top block 28 is adjustable vertically to different positions, and this arrangement together with a selection of a plurality of rear end blocks of different length, enables formation of cavities of different heights with corresponding different widths of slab. A plurality of sets of inner blocks may be provided, of different thicknesses, each set being utilized according to the desired thickness of the slab to be cast.

The bottom block 26 terminates short of the front end block 32 to provide an ingate passage 36 through which the molten metal is poured in the casting operation as will be referred to again hereinbelow. The front end block 32 has a setback 38 and the top block 28 terminates forwardly short of the setback 38 to provide a riser cavity or passage 40. Preferably the inner main surface 42 of the front end block and the front end surface of the top block 28 lie in a common plane.

FIG. 4 is a perspective view of a casting made in the mold of FIGS. 1, 2 and 3 which is completely regular in outline, being of rectangular shape in section on each major axis, with the additions of an ingate sprue 46 formed in the ingate passage 36 and a riser 48 formed in the riser cavity 40. However these excrescences project beyond the regular outline of the main portion of the slab and can be easily removed by cutting along the lines 460 and 48a, both of which are continuations of planar surfaces of the main portion of the slab. The resulting slab is completely rectangular and can be worked immediately from the casting into pieces suitable for fabrication, and is so worked according to the present invention and as described hereinbelow. It will be understood that the molten metal to be cast is poured through the ingate passage 36 into the cavity and when the cavity is filled, an excess amount of the metal flows into the riser cavity 40, and then upon contraction of the molten metal in the cavity proper, pursuant to its cooling, molten metal from the riser cavity recedes back into the main cavity to compensate for such contraction. There is always of course some excess metal that remains in the riser cavity which forms the riser 48 referred to, and this riser is later cut off as stated above.

FIGS. 5, 6, and 7 show a general plant layout utilizing a number of molds made according to the foregoing description. This plant layout not only utilizes a plurality of such molds, and preferably a large number of them, but also includes a novel arrangement for mounting and suspending the various blocks making up the mold for facilitating the casting operation and further treatment of the slabs. FIG. shows a building 50 having one or more rooms or spaces in which are arranged a plurality of molds or mold units or assemblies arranged in a row in, for example, the center of the room. The building includes a structural framework 54 including among other elements, spaced posts or columns 56, a floor 58 and overhead beams 60. The side blocks 22 and 24 are mounted in flasks 62 of structural steel work. These flasks each include a plurality of vertical members 64 spaced along the length of the blocks at the desired intervals, each member 64 having a foot 66 supporting the block at the bottom and an overhanging arm 68 engaging and supporting the top edge of the blocks. The flasks are provided with a plurality of hangers 70, such as three or four, for each flask 62 and are provided with rollers 72 riding on tracks 74 formed by the bottom flanges of the beam 60. These hangers 70 are enabled to roll for moving the side blocks 22 and 24 toward and from each other.

Preferably the flasks 62 are moved inwardly toward each other by suitable power means such as hydraulic or mechanical rams 76. These rams are provided in suitable number according to the size and massiveness of the molds which may be as long as I00 feet, for example, and in the neighborhood of 15 feet high. As here shown, these rams may be three in number vertically while they may be six or eight or l0 in number longitudinally.

Associated with each mold is a traversing car 78 riding on tracks 82. The car is provided with a support 84 which in turn supports the bottom block 26. Additionally, the rear end block is supported on the bottom block 26 (FIG. 6) and suitable bracing means 86 is provided for supporting the rear end blockin position. Additionally, the front end block 32 is supported on the car and carried therewith as described hereinbelow. 1

The top block'28 is suspended from above, for this purpose being secured to suitable supporting means such as a beam 88 (FIG. 7) preferably extending the full length of the top block and supported from above preferably by power devices such as hydraulic or mechanical rams 90 provided in such number to conveniently support the top block according to the length of the latter.

For assembling the mold, the side blocks 22 and 24 are moved apart and the car 78 is rolled into position carrying the bottom block, the rear end block and the front end block into the desired positions. The top block 28 is then lowered into position and thereafter the side blocks are moved up into closed position and thereafter the side blocks are moved up into closed position by the rams 76. The side blocks are moved into firm abutting engagement with the inner blocks, and the mold is then in condition to be filled.

The invention encompasses several different arrangements for assembling the mold, filling it, and then disassembling it. One arrangement is shown in FIGS. 5 and 6. In FIG. 6 are shown three rooms or bays 52a, 52b, and 52c. In the middle bay 52b the side blocks are mounted as described above in connection with FIG. 7. The car 78 can be moved between a position in the bay 52a in which it is separated from the main part of the mold, and into casting position in the bay 52b. The tracks 82 preferably are level in the bay 52a but in the bay 521; they are inclined forwardly. When the car is moved into the casting position in the bay 52b, its forward end is lowermost and the side blocks are suspended in the corresponding angle. This angle is preferably on the order of 3 from the horizontal in accordance with desired techniques in pressure casting. A poun'ng tank 92 in which is a ladle 94, is provided in the bay 52b, below the floor 58. A pouring tube construction 87 of suitable kind is provided on the tank which communicates with the cavity of the mold through the ingate passage 36. Upon development of superatrnospheric pressure in the tank 92, the molten metal in the ladle is forced up through the pouring tube into the cavity in known manner. In this system of pressure casting, the ingate passage is lowermost and as the steel flows into the cavity it flows up on inclined surfaces throughout the pouring operation, so as to prevent turbulence. Upon termination of the pouring step, the passage between the tank 92 and the mold cavity is shut off and the pouring tube moved out of contact with the mold by suitable and known means.

Upon the expiration of a suitable period of time, the slab solidifies, or partially solidifies, and thereafter the mold may be disassembled. This is done by first separating the two main side blocks 22 and 24 and then lifting the top block 28 from between the side blocks. Thereupon the car 78 is moved from the casting position out of the bay 52b into either bay 52a or 52c. In such a condition of the apparatus the slab 44 is exposed on its two broad sides and its top edge. Clamp means 98 of known kind is supported on a traveling crane 100 which includes a movable transverse beam 102 and a carriage 106 movable along the beam. The clamp means and crane are then actuated to lift the slab from the car 79, carry it to an opening in the floor 58 and lower it onto a car 108. This latter car, as shown in perspective, in FIG. 8 is provided with a plurality of stands operative for supporting the slabs therebetween in upright position. The car 108 can then be rolled along its tracks for removing the slabs out of that position for further treatment as referred to hereinbelow. The track 82 in the bay 520 is preferably at a level lower than the track in the bay 52a, to form an extension from the lower end of the inclined segment of the track in the middle bay 52b.

The feature of hanging the main side blocks of the mold provide a great advantage in that they are clear of the cars 78 and not supported thereby in any way, and consequently are more easily moved into and out of operative position than if they should be supported by the car. However the invention in its broad aspects includes all means of mounting the side blocks for movement into and out of operative position.

The car 78 may be utilized in connection with preconditioning the molds, such as for washing the main side blocks and coating them. For this purpose a unit 1 12 (FIG. 7, left) may be mounted on the car after the slab and the blocks supported thereon have been removed. The car with this unit mounted thereon is rolled or moved between the main side blocks and operated to produce a wash spray through the nozzles 1 14 for washing down the side blocks. This unit may be also include other spray nozzles 116 for applying a wash coating to the blocks. After the washing and coating operations are performed, the unit 112 is removed, and the inner blocks are again put in position on the car and the car put in operative position in association with the side blocks. The floor 58 may be provided with troughs 1 18 for draining the wash water.

The plant layout arrangement of FIG. 5 shows other features of the overall operation designed for high maximum production for relatively small area. For example, tube preheating furnaces 122 and a plurality of cover and tube holding furnaces 123 are provided at the center portion of the building between the two rows of mold units; in this space also are ladle transfer cars 125, and a hot metal transfer car 124.

FIG. 5 shows the mold units 20 at the right-hand side of the Figure as including only the main side blocks. The two end blocks and the bottom blocks are disposed on the cars 78 which are outwardly displaced from the mold units. This arrangement shows two such cars 78 for each mold unit which greatly increases the capacity of the molds because while one car is out of casting position for unloading the slab therefrom, the other car is being conditioned for the next casting operation. As each slab has been removed from its car, the washing and spraying unit 112 can be placed on that same car and the car moved between the side blocks for conditioning those blocks for later movement of the other car, with the end blocks and bottom blocks thereon, into position for casting.

FIG. 9 shows a similar arrangement in which the car 78 is movable in only one direction from the mold unit or assembly. In this case also the track 82 is inclined as at 82d in the position in which the complete mold is assembled for filling. AS in the previous case, the inclination of this portion of the track is in the neighborhood of 3 from the horizontal, the mold being arranged so that the ingate passage of the mold is lowermost.

Beyond the mold assembly is a transfer car 126 having a spray machine 128 mounted thereon for spraying at least certain of the parts of the mold. The transfer car is mounted for movement along the tracks 130 running transverse to the direction of movement of the car 78, and thus along the line of the mold units 20. The spray machine 128 is mounted on track elements 132 running in the direction of the tracks for the car 78. The transfer car 126 is movable into positions selectively with the various mold units and when in any such position the track elements 132 thereon are aligned with the tracks 82 of the mold unit whereupon the spray machine 128 can be rolled from the transfer car along the tracks 82 and between the main side blocks of the mold unit.

FIG. 10 shows an alternative form for washing or spraying the blocks of the mold. In the present instance, spray nozzles 134 depend from an overhead mounting on suitable supporting means that enables movement of the spray nozzles both vertically and longitudinally of the main side blocks for performing the washing operation or spraying the mold wash on the mold blocks.

Attention is directed next to FIGS. 11 and 12 showing an alternative arrangement for removing the castings from the molds and for further treating them, such as slotting, annealing, rolling etc. In FIG. 1 1 the main side blocks 22 and 24 are mounted in a manner similar to that described above in connection with FIG. 7, the present construction including atop beam 136 corresponding to the beam 60 of FIG. 7 and movable along tracks 138 extending in the direction of the main side blocks, for movement of those blocks together in such directions. The rams 76 described above areincluded in the present apparatus and are operable formoving the side blocks rail which in turn is supported on the pistons 142 of suitable rams 144, such as hydraulic or mechanical rams, in and spaced along a trench 146 in the floor 148 on which the posts 54 and other portions of the structure are mounted. The mold units are mounted a substantial distance above the floor 148 in order to enable lowering of the slab out of the mold unit and to provide additional space for accommodating other fixtures and operating members as described below. 7

The slab, upon being lowered out of the mold unit, is lowered into a control unit 149 including a pair of side members 150 and 152. The side member 150 preferably includes a plurality of fixed standards 154 supported as on the floor 148 spaced along the length of the mold unit. Supported in the standards 154 are a plurality of hydraulic or mechanical rams 156, preferably two in each standard, having pistons 158 with rollers 160 in their outer ends for engaging the slab when the latter is in lowered position. Preferably also on each standard 154 is another hydraulic or mechanical ram 162 having a piston 164 with a roller 166 in its outer end cooperating with a counterpart in the opposed unit 152 for guiding the slab in its lowering movements.

The side members 152 includes a swingable member 168 pivoted at 170 on suitable means such as a base member 172. The member 168 moves between an upright position shown in full lines and a lower position shown in dot-dash lines, in the latter position serving as a table.

The swingable member 168 is controlled by a plurality of hydraulic or mechanical rams 174 spaced longitudinally along the member and having cylinders 176 mounted in a trench 178 in the floor 148. The swingable member 168 is provided with a plurality of hydraulic or mechanical rams 180 arranged preferably in two rows and each row including a plurality spaced along the length of the swingable member. Preferably the rams 180 are the same in number and are opposed to respective ones of the rams 156 whereby those on each of the side members 150 and 152 produce counteracting thrusts. The pistons 182 of the rams may have flat heads for engaging the slab.

Also mounted on the swingable member 168 are a plurality of rams 184 along the top, or swinging, edge of the swingable member, having pistons 186 provided with rollers 188 in their extended ends. These rams 184 and associated elements are preferably the same in number as the rams 162 and respectively aligned therewith.

Also incorporated in the swingable member 168 are additional rams 190 spaced longitudinally along the mold unit and each having a piston 192 operatively associated with a retractable base 194. The retractable base acts as a support for the slab when the latter is lowered, and can be extended and retracted for that purpose, as explained below. The retractable base 104 may be a single long member, or made up of a plurality of separate and spaced plungers each actuated by the respective ram 190.

In the assembling of the mold unit for performing a casting operation, the rams 144 are extended for moving the bottom block 26 up into position between the main side blocks, and the other inner blocks are also-put into position. The rear end block and the front end block may be supported by suitable means such as standards 198 and 200 (FIGS. 12 and 13), supported on an upper floor 202. The supports or standards 198 and 200 are'relatively narrow to enable longitudinal movement of the main side blocks therepast upon relatively slight separation of side blocks. When the inner blocks are all in position, the main side blocks are moved toward each other into firm engagement'with all of the inner blocks, into assembled position, and the mold unit is then in condition for pouring molten metal thereinto for the casting operation, upon operative communication with pouring means here indicated generally at 204 (FIG. 12) which may include a pressure tank and a ladle therein. The pouring step is performed as described above, and upon completion thereof the mold is separated from the pouring means and the latter moved from the pouring position, as to the right as shown in FIG. 12. Upon solidification of the molten metal to the desired extent, to form the slab 44, the main side block 30 and front end block retracted slightly. Thereupon, the rams 144 (FIG. 11) are retracted, the swingable member or table 168 having been previously raised to its upper position, and this retracting and lowering movement of the rams 144 lets the slab down. Where the main side blocks are separated only slightly, and if desired only the clamping pressure may be relieved without spatially moving the side blocks, the slab in its lowering movements produces a shearing or wiping action on the side blocks and performs a clean separating movement.

Upon continued lowering movement of the slab, it is brought between the guide rollers 166 and 188, these rollers having been theretofore put into the desired position for performing a guiding action on the slab and preventing its being accidentally tilted. The slab is then lowered further to a position in which its lower edge is only slightly above the upper surface of the retractable base 194, as indicated by the dotdash line 26a representing the then upper surface of the bottom block 26. Then the rams 156 and 180 are both extended until they are brought into firm clamping engagement with the slab, sufficient to support the slab vertically. Thereupon the rams 144 are lowered further, separating the bottom block 26 from the slab and moving it down below the retractable base 194 and then the hydraulic rams 190 are extended for moving the retractable base out into supporting position as shown in full lines. Thereupon the slab is released until it lowers into engagement with the retractable base. Following this, the swingable member or table 168 is swung down into lowered horizontal position, but in the initial portion of this movement, the rams 156 are extended to retain the slab against the heads of the pistons 182, until the swingable member 168 has been lowered sufficiently for the slab to assume a stable position thereon.

The swingable member or table 168 in its lowered position may be supported by the rams 174, or if desired, by fixed supports 206 adjacent the outer swinging end of the member. The swingable member 168 is provided with a plurality of rollers 208 driven by suitable means (not shown). After the swingable member has been lowered to its horizontal position the hydraulic rams 180 are retracted and the slab 44 is let down on the rollers 208. These rollers are relatively close together and distributed throughout the area of the table and the slab is thereupon ready for conveyance to other positions or stations for additional treatment thereof. FIG. 12 shows stations 210 and 212 which may be, for example, rolling mills of suitable kind such as shown in FIG. 14 having rolls for slotting the slab. Another station 214 may be provided and utilized, for example, for burning off the riser and ingate sprue from the slab. Additionally a furnace 216 may be provided for annealing the slab.

The arrangement shown in FIGS. 12 and 13 includes an alternative arrangement in which the slide blocks of the mold are moved out of their assembly location for performing washing and coating operations. After the casting operation, the mold blocks are separated to clear the support 198 and then moved longitudinally-past a wash unit or station 218 and a coating spray unit or station 220, or to the left as shown in FIGS. 12 and 13. The stations 218 and 220 are so dimensioned and located that the side blocks in their movement referred to straddle the stations. These stations include the usual apparatus for performing the washing and spraying functions, having nozzles distributed throughout the necessary area for performing those functions.

The arrangement may also include a space indicated generally at 222 beyond the stations 218 and 220 into which the side blocks are moved, which may be utilized for additional operations such as machining the mold blocks.

All of the mold blocks have inner surfaces that are completely regular or planar for defining a correspondingly regularly shaped slab, with the exception of the openingsfor accommodating the necessary pouring and risering functions. The ingate sprue and riser resulting therefrom constitute the only irregularities and these can be easily and quickly removed from the slab to produce the desired completely uniform and regular slab. This slab can then be further treated as by slotting, rolling, etc. for producing pieces that are capable of immediate fabrication without additional operations for this purpose. For example, the slabs do not require scarfing or other treatment operations except, as referred to above, removal of the ingate sprue and riser.

While I have disclosed herein certain preferred forms of the invention, it will be understood that changes may be made therein within the spirit and scope of the appended claims.

1. Mold apparatus for casting molten metal comprising side blocks movable toward and from each other, a plurality of inner blocks, including a bottom block, movable into and out of position at least partially within the projection of the side blocks, the side blocks when moved toward each other being capable of engaging the inner blocks on opposite sides thereof and together with the inner blocks when in engagement therewith forming a casting cavity, means for supporting the bottom block independently of the remaining blocks and for moving the bottom block together with a cast product which has been formed in the cavity out from between the side blocks for exposing the cast product for removal therefrom.

2. The mold apparatus set out in claim 1 wherein the means for supporting the bottom block includes a car movable generally horizontally from the location of the engagement of the inner blocks for exposing the slab longitudinally beyond the side blocks.

3. The mold apparatus set out in claim 2 including tracks for accommodating the movable car, the tracks being inclined at the location of the engagement of the side blocks for positioning the car and the bottom block at an inclination and wherein the side blocks and the remaining inner blocks are respectively inclined at the inclination of the bottom block.

4. The mold apparatus set out in claim 1 wherein the inner blocks include a rear end block and a front end block, and the means for supporting the bottom block also supports the rear end block and the front end block ans is operative for transporting such three blocks together with the cast product from between the side block to a position exposing the cast product.

5. The mold apparatus set out in claim 1 wherein the means for supporting the bottom block includes a movable car said inner blocks include, in addition to said bottom block, a rear end block, a front end block and a top block, means is provided for supporting the top block independently of the other blocks, the car is operative for supporting the bottom block, the rear end block, and the front block, as well as the cast product, and the means for supporting the top block is capable of removing the top block from the assembled mold for enabling components supported by the car to be removed from the side blocks.

6. Mold apparatus set out in claim 1 wherein means is provided for supporting the side blocks in a downwardly hanging position.

7. The mold apparatus set out in claim 6 wherein the inner blocks include a top block, and means is provided for supporting the top block in a downwardly hanging position independently of the other blocks.

8. The mold apparatus set out in claim 6 wherein the means for supporting the side blocks include overhead tracks, and rollers secured to the side block and engaged with the overhead tracks for movement of the side blocks toward and from each other.

9. The mold apparatus set out in claim 8 including power means for moving the side blocks toward and away from each other.

10. The mold apparatus set out in claim 1 wherein means for supporting a bottom block is provided at opposite ends of the side blocks, and means being alternately movable between and withdrawn from the side blocks from the means opposite ends.

11. The invention set out in claim 1 wherein the support for the cast product is vertically movable, means is provided for lowering the bottom block and thereby lowering the cast product therewith, and means is provided below the side blocks for receiving the cast product and conveying it from the location of the side blocks.

12. The invention set out in claim 11 wherein the means below the side blocks for receiving the cast product includes a swingable member movable from an upper position in which the means receives the cast product, to a lowered position at right angles thereto and operative for lowering the cast product correspondingly to a horizontal position.

13. The invention set out in claim 1 wherein the bottom block is vertically movable, the means for supporting the bottom block is operative for lowering that block and the cast product thereon, means is provided below the side blocks including a fixed upright member and a second member swingable between an upright position and a lower horizontal position, gripping elements in each of the members, and those of the first member being for retaining the cast product in stable position against the swingable member as the swingable member is swung from upright position toward lower horizontal position.

14. The invention set out in claim 13 in conjunction with a supporting floor for the upright members, power means is provided for moving said support and bottom block, and power means is provided for swinging the swingable member between its opposite positions, said power means extending downwardly into trenches in the floor.

15. The invention set out in claim 11 wherein the means below the side blocks for receiving the cast product includes a swingable member movable from an upper position in which the means receives the cast product, to a lowered position at right angles thereto and operative for lowering the cast product correspondingly to a horizontal position, said swingable member includes a base member extendable into and retractable from a position in the vertical projection of the cast product, gripping members are provided operative for supporting the cast product in the absence of the bottom block, whereby to enable separation of the bottom block, from the cast product, gripping members are provided operative for supporting the cast product in the absence of the bottom block, whereby to enable separation of the bottom block from the cast product, and an extendable base in the swingable member for supporting the cast product upon release of the gripping action of said gripping elements.

16. The invention set out in claim 1 wherein the bottom block is vertically movable, the means for supporting the bottom block is operative for lowering that block and lowering the cast product thereon, means is provided below the side blocks including a fixed upright position and a lower horizontal position, said members including gripping elements in each of the members and those of the first member being extendable for retaining the cast product in stable position against the swingable member as the swingable member is swung from upright position toward lower horizontal position, the swingable member is provided with a plurality of rollers disposed for supporting the cast product when the swingable member is in its lowered position, means is provided for driving the rollers thereby forming conveyor means for conveying the cast product from the swingable member, and additional conveyor means is provided for receiving the cast product from the first conveyor means for further treatment of the cast product.

17. The invention set out in claim 1 wherein means is provided for moving the side blocks also in longitudinal direction for removing them from the assembly location whereby to expose them for other treatments at positions remote from the assembly location.

18. The invention set out in claim 17 wherein the inner blocks include, in addition to the bottom block, end blocks and a top bloc}; means is provided for suspending the top block in downwardly hanging position, means is provided for supporting the end blocks in vertical zones extending longitudinally of the side blocks and not materially greater than the thickness of the end blocks in direction between the side blocks, whereby to enable removal of the side blocks in longitudinal direction beyond the end blocks and the supporting means therefor, and wherein the combination also includes a treating station longitudinally beyond one of the end-block supporting means and disposed in said zone whereby the side blocks in being moved to said remote position straddle said treating station, and means is provided in said treating station for treating the opposed inner surfaces of the side blocks as the side blocks are moved thereby.

19. In an article casting apparatus, a plurality of upper mold elements, a bottom mold element on which the cast article is adapted to rest on completion of the casting operation, a carriage for supporting said bottom mold element, supporting and guiding means for the carriage constructed to allow the carriage to move in a longitudinal direction towards and away from said upper mold elements, and means for effecting said movement of said carriage.

20. A mold construction comprising: main side blocks; means for mounting the main side blocks for movement toward and away from each other; a plurality of inner blocks including a front end block, a rear end block, a bottom block, and a top block, positioned between and engaged by the main side blocks in an operative position and together with the main side blocks defining a longitudinal casting cavity in the shape of a slab disposed on edge; means for supporting the top block from above and lowering and raising the top block into and out of operative position relative to the main side blocks; a car supporting the bottom block and having standards supporting the front end block and the rear end block against longitudinal displacement, said car being movable into a position in which the bottom and end blocks carried thereby are in operative casting position in relation to the main side blocks, and movable from said operative position with a casting formed in the mold.

21. Mold apparatus for casting molten metal comprising a mold having a bottom mold element and a plurality of upper mold elements including opposed side mold elements extending in a given direction, said bottom mold element being mounted independent of said opposed side mold elements and intermediate said opposed side mold elements, said upper mold elements and said bottom mold element defining a cavity for a cast article, said cast article being supported by said bottom mold element, and means for moving said bottom mold element together with a cast article which has been formed in said cavity away from said opposed side mold elements. 22. Mold apparatus according to claim 21 including support means to engage and hold said cast article during movement away from said opposed side mold elements in substantially the same position the cast article assumed during casting.

23. Mold apparatus according to claim 21 wherein said means comprise spaced rails extending in the direction of said opposed side mold elements and away from said upper mold elements, a car supporting said bottom mold element and said cast article, and wheels on said car engaging said rails for movement of said car to and from said opposed side mold elements.

24. Mold apparatus according to claim 23 including a carriage for moving said cast article away from said rails, said carriage being movable in a direction normal to thetravel of said car.

25. Mold apparatus according to claim 24 including holding means mounted on said carriage to engage and hold said cast article in substantially the same position the cast article assumes when it is moved from said opposed side mold element on said car.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,604,497 Dated September 14, 1971 Inventor-(s) Edmund Q y ter It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 6, line 58, "104" should read 194 Column 7, line 7, "the main side block 30 and front end block retracted slightly" should read the main side blocks are separated, at least slightly, and the rear end block 30 and front end block retracted slightly Column 9, line 54, after "upright" insert member and a second member swingeable between an upright Signed and sealed this 11th day of April 1972.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. ROBERT GOTTSCHALK Attesting Officer Commissioner of Patents RM P0-1050 (10-69] USCOMM-DC 60376-F'69 US. GOVERNMENT PRINTING OFFICE" I909 0-106-334 

1. Mold apparatus for casting molten metal comprising side blocks mOvable toward and from each other, a plurality of inner blocks, including a bottom block, movable into and out of position at least partially within the projection of the side blocks, the side blocks when moved toward each other being capable of engaging the inner blocks on opposite sides thereof and together with the inner blocks when in engagement therewith forming a casting cavity, means for supporting the bottom block independently of the remaining blocks and for moving the bottom block together with a cast product which has been formed in the cavity out from between the side blocks for exposing the cast product for removal therefrom.
 2. The mold apparatus set out in claim 1 wherein the means for supporting the bottom block includes a car movable generally horizontally from the location of the engagement of the inner blocks for exposing the slab longitudinally beyond the side blocks.
 3. The mold apparatus set out in claim 2 including tracks for accommodating the movable car, the tracks being inclined at the location of the engagement of the side blocks for positioning the car and the bottom block at an inclination and wherein the side blocks and the remaining inner blocks are respectively inclined at the inclination of the bottom block.
 4. The mold apparatus set out in claim 1 wherein the inner blocks include a rear end block and a front end block, and the means for supporting the bottom block also supports the rear end block and the front end block ans is operative for transporting such three blocks together with the cast product from between the side block to a position exposing the cast product.
 5. The mold apparatus set out in claim 1 wherein the means for supporting the bottom block includes a movable car said inner blocks include, in addition to said bottom block, a rear end block, a front end block and a top block, means is provided for supporting the top block independently of the other blocks, the car is operative for supporting the bottom block, the rear end block, and the front block, as well as the cast product, and the means for supporting the top block is capable of removing the top block from the assembled mold for enabling components supported by the car to be removed from the side blocks.
 6. Mold apparatus set out in claim 1 wherein means is provided for supporting the side blocks in a downwardly hanging position.
 7. The mold apparatus set out in claim 6 wherein the inner blocks include a top block, and means is provided for supporting the top block in a downwardly hanging position independently of the other blocks.
 8. The mold apparatus set out in claim 6 wherein the means for supporting the side blocks include overhead tracks, and rollers secured to the side block and engaged with the overhead tracks for movement of the side blocks toward and from each other.
 9. The mold apparatus set out in claim 8 including power means for moving the side blocks toward and away from each other.
 10. The mold apparatus set out in claim 1 wherein means for supporting a bottom block is provided at opposite ends of the side blocks, and means being alternately movable between and withdrawn from the side blocks from the means opposite ends.
 11. The invention set out in claim 1 wherein the support for the cast product is vertically movable, means is provided for lowering the bottom block and thereby lowering the cast product therewith, and means is provided below the side blocks for receiving the cast product and conveying it from the location of the side blocks.
 12. The invention set out in claim 11 wherein the means below the side blocks for receiving the cast product includes a swingable member movable from an upper position in which the means receives the cast product, to a lowered position at right angles thereto and operative for lowering the cast product correspondingly to a horizontal position.
 13. The invention set out in claim 1 wherein the bottom block is vertically movable, the means for supporting the bottom blocK is operative for lowering that block and the cast product thereon, means is provided below the side blocks including a fixed upright member and a second member swingable between an upright position and a lower horizontal position, gripping elements in each of the members, and those of the first member being for retaining the cast product in stable position against the swingable member as the swingable member is swung from upright position toward lower horizontal position.
 14. The invention set out in claim 13 in conjunction with a supporting floor for the upright members, power means is provided for moving said support and bottom block, and power means is provided for swinging the swingable member between its opposite positions, said power means extending downwardly into trenches in the floor.
 15. The invention set out in claim 11 wherein the means below the side blocks for receiving the cast product includes a swingable member movable from an upper position in which the means receives the cast product, to a lowered position at right angles thereto and operative for lowering the cast product correspondingly to a horizontal position, said swingable member includes a base member extendable into and retractable from a position in the vertical projection of the cast product, gripping members are provided operative for supporting the cast product in the absence of the bottom block, whereby to enable separation of the bottom block, from the cast product, gripping members are provided operative for supporting the cast product in the absence of the bottom block, whereby to enable separation of the bottom block from the cast product, and an extendable base in the swingable member for supporting the cast product upon release of the gripping action of said gripping elements.
 16. The invention set out in claim 1 wherein the bottom block is vertically movable, the means for supporting the bottom block is operative for lowering that block and lowering the cast product thereon, means is provided below the side blocks including a fixed upright position and a lower horizontal position, said members including gripping elements in each of the members and those of the first member being extendable for retaining the cast product in stable position against the swingable member as the swingable member is swung from upright position toward lower horizontal position, the swingable member is provided with a plurality of rollers disposed for supporting the cast product when the swingable member is in its lowered position, means is provided for driving the rollers thereby forming conveyor means for conveying the cast product from the swingable member, and additional conveyor means is provided for receiving the cast product from the first conveyor means for further treatment of the cast product.
 17. The invention set out in claim 1 wherein means is provided for moving the side blocks also in longitudinal direction for removing them from the assembly location whereby to expose them for other treatments at positions remote from the assembly location.
 18. The invention set out in claim 17 wherein the inner blocks include, in addition to the bottom block, end blocks and a top block means is provided for suspending the top block in downwardly hanging position, means is provided for supporting the end blocks in vertical zones extending longitudinally of the side blocks and not materially greater than the thickness of the end blocks in direction between the side blocks, whereby to enable removal of the side blocks in longitudinal direction beyond the end blocks and the supporting means therefor, and wherein the combination also includes a treating station longitudinally beyond one of the end-block supporting means and disposed in said zone whereby the side blocks in being moved to said remote position straddle said treating station, and means is provided in said treating station for treating the opposed inner surfaces of the side blocks as the side blocks are moved thereby.
 19. In an article casting apparatus, a plurality of upper mold elements, a bottom mold element on which the cast article is adapted to rest on completion of the casting operation, a carriage for supporting said bottom mold element, supporting and guiding means for the carriage constructed to allow the carriage to move in a longitudinal direction towards and away from said upper mold elements, and means for effecting said movement of said carriage.
 20. A mold construction comprising: main side blocks; means for mounting the main side blocks for movement toward and away from each other; a plurality of inner blocks including a front end block, a rear end block, a bottom block, and a top block, positioned between and engaged by the main side blocks in an operative position and together with the main side blocks defining a longitudinal casting cavity in the shape of a slab disposed on edge; means for supporting the top block from above and lowering and raising the top block into and out of operative position relative to the main side blocks; a car supporting the bottom block and having standards supporting the front end block and the rear end block against longitudinal displacement, said car being movable into a position in which the bottom and end blocks carried thereby are in operative casting position in relation to the main side blocks, and movable from said operative position with a casting formed in the mold.
 21. Mold apparatus for casting molten metal comprising a mold having a bottom mold element and a plurality of upper mold elements including opposed side mold elements extending in a given direction, said bottom mold element being mounted independent of said opposed side mold elements and intermediate said opposed side mold elements, said upper mold elements and said bottom mold element defining a cavity for a cast article, said cast article being supported by said bottom mold element, and means for moving said bottom mold element together with a cast article which has been formed in said cavity away from said opposed side mold elements.
 22. Mold apparatus according to claim 21 including support means to engage and hold said cast article during movement away from said opposed side mold elements in substantially the same position the cast article assumed during casting.
 23. Mold apparatus according to claim 21 wherein said means comprise spaced rails extending in the direction of said opposed side mold elements and away from said upper mold elements, a car supporting said bottom mold element and said cast article, and wheels on said car engaging said rails for movement of said car to and from said opposed side mold elements.
 24. Mold apparatus according to claim 23 including a carriage for moving said cast article away from said rails, said carriage being movable in a direction normal to the travel of said car.
 25. Mold apparatus according to claim 24 including holding means mounted on said carriage to engage and hold said cast article in substantially the same position the cast article assumes when it is moved from said opposed side mold element on said car. 